Mechanical Design

 During my engineering internship at KEEL/MERRILL, I designed a support structure for a HAB (Habitability) module used in submarine construction. The objective was to enable safe vertical suspension of the cylindrical module for interior work, while ensuring it remained stable during crane-assisted handling and assembly operations.

 I created the full design in CAD and conducted center of gravity and tipping force calculations to verify that the stand would remain stable under dynamic loading. I also performed stress analysis to confirm that the structure could safely support the module during lifting and assembly. To ensure compatibility with real-world shop floor operations, I factored in overhead crane clearances, part orientation flexibility, and load distribution.

 To increase the versatility of the system, I developed a set of custom lifting hooks that could be used in multiple orientations—allowing the stand to be adapted for current and future components with varying geometries. Additionally, I performed a return-on-investment (ROI) analysis to evaluate the long-term value of the solution, showing that the modular design would reduce the need for repeated fabrication on future projects.

 This project strengthened my skills in mechanical design, structural analysis, and cost-performance optimization, while reinforcing the importance of flexibility and safety in real-world engineering applications.

 During my internship at KEEL/MERRILL, I supported the installation of a new press brake system at the REPUBLIC facility in Alma, Michigan. After the machine was recessed into the shop floor, I helped design and install a custom flooring system to safely cover the surrounding pit and ensure full structural integrity during high-force operations.

 I developed the support framing using tolerance-based design principles to achieve a tight, precise fit with the existing floor. I conducted material comparisons and basic stress analysis to ensure the platform could withstand repeated loading from both the press brake and the heavy components it would process. The selected materials and framing layout were chosen to prevent deflection, maintain safety standards, and support long-term durability in a demanding industrial environment.

 The final installation involved anchoring the platform and validating the load-bearing capacity through practical testing. This project reinforced my skills in structural fitment, material evaluation, and fabrication planning—highlighting the importance of detail-oriented design in real-world manufacturing settings.

 During my internship at KEEL/MERRILL, I contributed to two fabrication-focused projects for the Bath Iron Works (BIW) paint room, each aimed at improving functionality and safety in the shipbuilding environment.

 For the manhole cover, I designed a custom circular steel plate to allow safe floor access while supporting foot traffic. The design included precision hole placement along the perimeter to allow secure bolting to a mating surface, ensuring worker safety and structural integrity. I selected appropriate hardware and confirmed compatibility through SolidWorks modeling, considering the load demands of a high-use industrial setting.

 The second project was a paint room practice board, built to simulate real-world painting conditions and allow operators to refine their technique before painting final components. I designed the board with the correct materials and geometry to accurately represent target part surfaces and integrated it into the existing workflow for hands-on training. This contributed to both quality control and operator efficiency.

 Together, these projects enhanced safety, training, and repeatability in the paint room. They involved skills in mechanical design, fabrication planning, and CAD modeling—all applied in a production-oriented setting with direct operational impact.

 While interning at KEEL/MERRILL, I assisted in diagnosing and repairing a malfunctioning electron beam welding system used for fabricating precision titanium components in aerospace applications. The system relies on a high-voltage cabinet that houses the power supply and control circuitry responsible for generating and directing the electron beam during welding.

 Working alongside a secondary service company, I helped systematically isolate the issue through performance testing and system-level diagnostics. After narrowing the fault to the high-voltage cabinet, I disassembled the internal components and traced wiring configurations using circuit schematics. I then reconfigured and reinstalled the electrical circuits, ensuring safe and correct operation in accordance with the original system design.

 This project required close attention to safety protocols, high-voltage handling, and accurate interpretation of technical diagrams. It gave me hands-on experience with power systems, fault isolation, and the integration of control electronics in high-performance manufacturing environments—critical skills for engineering roles in advanced aerospace systems.